Star-point retrofit for Suzlon generators

Engineering, manufacturing and validation of a dedicated solution for ELIN generators installed in Suzlon S88 wind turbines, designed for uptower intervention.

From a critical failure to an industrially deployable solution

A recurring failure cannot always be resolved by replacing the affected component. In certain ELIN generators installed in Suzlon S88 wind turbines, the rotor star-point area presented challenges in access, insulation and mechanical strength that called for a fundamental redesign.

OREMOTOR approached the project as an end-to-end development: failure analysis, alternative design, prototype manufacture, fit checks on the machine and definition of an intervention procedure suitable for uptower work.

The challenge

The technical diagnosis identified damage to the star-point connection affecting adjacent winding areas. The available geometry, working conditions inside the generator and insulation requirements made a conventional repair insufficient.

• Fit within the rotor’s actual available space.
• Provide stable mechanical support.
• Arrange and protect the electrical connections.
• Facilitate assembly and inspections.
• Enable planned intervention in the wind turbine where the specific conditions allow.

OREMOTOR’s response

OREMOTOR’s engineering team developed a dedicated kit to rebuild and reorganise the star point. It incorporated support segments, connecting bridges, conductors, fasteners and insulation elements conceived as a complete system.

Development went beyond design. Initial prototypes were fitted on the machine, interferences and fit discrepancies were identified, and successive modifications were introduced until a configuration suitable for manufacturing and assembly was achieved. This testing and refinement phase was essential to turn a technical concept into a repeatable solution.

OREMOTOR also prepared the manufacturing documentation and intervention procedure: access, dismantling, preparation, positioning and securing the assembly, connection, insulation, electrical checks and final reinstatement.

Engineering designed for uptower work

A distinctive feature of the project was considering, from the outset, how the solution would be installed inside the wind turbine. The work sequence and kit configuration were designed to enable controlled intervention in the nacelle by qualified personnel following the relevant technical procedure.

OREMOTOR supplied not just custom-made components, but a documented engineering solution ready for implementation: from initial diagnosis to kit supply and the project’s associated deliveries.

Outcome

The project produced a dedicated star-point retrofit for this generator type, validated through prototypes, on-machine fit checks and technical manufacturing and installation documentation. Following development, subsequent kit orders and deliveries demonstrated its transition from prototype to an industrially deployable solution.

This case illustrates OREMOTOR’s approach: analyse the cause, design for real operating conditions, manufacture, validate and support implementation.